SmartKKS Basic version technical Documentation - Leutron · SmartKKS Basic version technical...

SmartKKS Basic Version Technical Documentation

Version 1.0

SMARTKKS BASIC VERSION

TECHNICAL DOCUMENTATION

LEUTRON GmbH Lightning and Surge Protection Humboldtstr. 30/32 D-70771 Leinfelden-Echterdingen Germany phone.: +49(0)711 / 9 47 71 – 0 fax.: +49(0)711 / 9 47 71 – 70 [email protected]

SmartKKS Basic version technical Documentation

Müller Matthias, Version: 01.03.2017 of 16

Contents

CONTENTS ............................................................................................................................................................. 2

1 INTRODUCTION .................................................................................................................................................. 3

2 LAYOUT OF THE TECHNOLOGICAL EQUIPMENT IN THE BASIC VERSION .............................................................. 4

2.1 TECHNICAL DATA, OVERVIEW ................................................................................................................................ 4

2.2 HOUSING ................................................................................................................................................................ 5

2.3 OVERVIEW OF THE COMPONENTS ......................................................................................................................... 6

2.4 POWER SUPPLY ...................................................................................................................................................... 6

2.5 PROTECTIVE CURRENT MODULE ............................................................................................................................ 7

2.6 MEASUREMENT MODULE ...................................................................................................................................... 8

2.7 MAIN MODULE ..................................................................................................................................................... 10

2.8 WEB INTERFACE UNIT .......................................................................................................................................... 11

2.9 FAN ....................................................................................................................................................................... 11

3 SMARTKKS SOFTWARE PLATFORM ................................................................................................................... 12

4 FUNCTIONS OF THE SMARTKKS BASIC VERSION ............................................................................................... 14

4.1 CCP OPERATION ................................................................................................................................................... 14

4.1.1 PARAMETRIZATION ............................................................................................................................................ 14

4.1.2 ROUTINE MEASUREMENT .................................................................................................................................. 14

4.1.3 ONLINE MEASUREMENT .................................................................................................................................... 15

4.2 ANALYSIS OF EXTERNAL INTERFERENCES ............................................................................................................. 15

4.3 DETECTION OF EXTERNAL CONTACTS .................................................................................................................. 16

5 QUICK REFERENCE FOR THE SMARTKKS INSTALLATION .................................................................................... 16



1 Introduction

The SmartKKS system is used for the cathodic corrosion protection of buried metallic objects to be protected, such as gas pipelines. By applying external current, the corrosion process is minimised to a technically negligible rate.

The technical equipment of the SmartKKS system is a combination of protective current unit, integrated measuring technology and integrated remote control technology. Figure 1 shows the principle of cathodic corrosion protection (CCP, KKS in German).

Figure 1: Overview of the CCP principle

In general, the SmartKKS instruments communicate with the control and evaluation software, also called control level, via the mobile communications network. It is also possible to connect the instruments via an existing communications infrastructure of the operator, see Figure 2.

Figure 2: Communications structure



A software is provided for the controlling of the SmartKKS instruments and the evaluation of the readings. As of yet, the software is available as web service, which means that a web server provides a web site with which the user can control the instruments and carry out all evaluations and analyses of the measured data. The SmartKKS web server and the SmartKKS web site feature appropriate safety and security mechanisms to prevent unauthorised access or data manipulation.

In addition to a CCP operation in accordance with the provisions laid down in the rules set of the German Technical and Scientific Association for Gas and Water DVGW, the system is capable of detecting external contacts with the protected object that have a short-time effect and a high resistance compared to the protected object. With this technology, an additional danger prevention can be implemented, for instance on high-pressure gas pipelines, based on cathodic corrosion protection.

SmartKKS allows for a permanent monitoring of the protected object, which is referred to as CCP online monitoring.

2 Layout of the technological equipment in the basic version

2.1 Technical data, overview

Electrical output:

Power supply and external interference 400 W

Protection voltage: max. 42 V, continuously adjustable

Protective current: max. 2 x 12.5 A = 25 A

Voltage measurement: Measurement resolution from a few µV to 150 V

Current measurement: Measurement resolution from a few µA to >100 A

Time synchronisation: DCF77, time server

Communication: UMTS mobile telecommunications network, Ethernet cable-based connection, optical fibre cabling, …

VPN encryption

Basic protection against overvoltage: Basic protection in accordance with EMC Directive



2.2 Housing

The housing is made of aluminium. To mount the housing an angled rail is fixed to the wall into which the housing is hinged via a bracket construction. For an additional fixing, the housing is screwed to the wall through the two mounting lugs at the bottom of the housing.

The housing is sealed against dust penetration.

Housing dimensions:

(H x W x D) 400 x 400 x 221 mm

Weight:

7 kg

Housing connection for equipotential bonding

Figure 3: Housing dimensions



2.3 Overview of the components

Figure 4: Technical components

2.4 Power supply

A power unit with the following operating data is used for the primary power supply of the SmartKKS instrument:

Input

Input voltage: 85...265 V AC/90...250 V DC

Input current: 5.1 A (100 V AC); 2.4 A (240 V AC)

Max. inrush current after 1 ms: 11 A (230 V AC)

Efficiency: 0.94 (230 V AC)

External pre-fuse: max. 20 A (T), wire protection

Frequency: 50...60 Hz

Power supply module Remote control module

Measurement module

Fan

Primary power supply

Mobile antenna



Output

Output voltage: 48 V DC (SELV), ±1 %; 48...56 V adjustable

Power boost: Iout N × 150 % (min. 4 s)

Output current: 10 A

Mains failure bridging: min. 30 ms (100 V AC); 10 A (48 V DC)

Residual ripple: max. 50 mVeff

Spikes: max. 200 mV p-p

Instrument protection: Short circuit and overload proof

LED display: green LED: OK; red LED: Overload, overheating or short circuit

General data

Standards: EN 60950-1, EN 61204-3, EN 55011 B, EN 61000-3-2, SEMI F47

Relative humidity: 5...95 %, condensation not permissible

Efficiency: 95 %

Type of mounting: Snap-on to mounting rail TH35 (EN 60715)

Temperature range: -25...+60°C, ...+70°C derating (storage temperature -40...+80°C)

2.5 Protective current module

The protective current module provides the voltage supply of the measurement module and the main module on the one hand.

On the other, the protective current module provides the CCP protection voltage US and the CCP protective current IS.

Figure 5: Protective current module



Input: 48 V

Terminals: 0.25-4 mm2 / 24-12 AWG

Input -IS1/-IS2: Negative output channel to connect the protected object as cathode

2 channels

12.5 A per channel

When using one protected object, both output channels must be connected

Terminals: 0.25-mm2 / 24-12 AWG

Output + Anode +: Positive output channel to connect the anode

2 channels

1…42 V

Both cables must be connected to the anode

Terminals: 0.25-mm2 / 24-12 AWG

AUX Input: Reserved, without function

LEDs

Status LED: Green Steady OK

Green Flashing Starting

Red Steady Error

Red Flashing Warning

Analysis LED: Green Steady Analysis active

Green Off Analysis inactive

Red Steady Interference detected

2.6 Measurement module

The DCF77 antenna, temperature sensors, current shunts and objects whose electric potentials shall be measured are connected to the measurement module.

The DCF77 antenna is used to synchronize the system time with the long-wave transmitter in Mainflingen near Frankfurt am Main. With this time signal sender, the CCP measuring instruments and the CCP protective current units can be synchronised to each other regarding time.

In order to measure the potentials of the connected protected objects, such as a cathodically protected pipeline, in relation to a permanent reference electrode, the objects to be measured must be connected to the measurement module. The measurement module offers the following connection options.



Figure 6: Measurement module

Input terminals to measure electric voltage:

1: Ref Permanent reference electrode

2: U1+ Potential of protected object 1, pipeline 1

3: U2+ Potential of connected anode

4: U3+ Potential of protected object 2, pipeline 2

5: U4+ Customised potential

Measuring shunt terminals to measure the current:

1: Ref Permanent reference electrode (optional)

2: I1- Signal input to measuring shunt

3: I1+ Signal input to measuring shunt

4: I2- Signal input to measuring shunt

5: I2+ Signal input to measuring shunt

Input terminals of DCF77 antenna (Meinberg RU-226)

1: 0V GND power (black)

2: +5V VDD power (red)

3: (empty) Reserved

4: Poff Power off (brown)

5: DCF DCF signal (orange)



Input terminals for temperature

1: 0V PT reference

2: PT2 PT1000 input terminal

3: PT1 PT1000 input terminal

4: SW Fan power supply (connected)

5: +5V Fan power supply

LEDs

Power LED: Green Steady OK


Sync LED: Yellow Flashing DCF77 signal

Status LED: Red Steady Error


2.7 Main module

The main module is the central component of the SmartKKS instrument. It takes care of the communication with the control level, the controlling of the protective current module and the evaluation of the readings transmitted by the measurement module.

Figure 7: Main module



The main module features a built-in touch display which allows you to view and configure the key operating data.

Ports:

USB 2.0 For USB storage media or for the 5 V voltage supply of additional instruments

microSD microSD memory card, used internally by the system

Ethernet RJ45 port to connect a PC/notebook or a router

UMTS microSIM card slot for a mobile telephone card

SMA port to connect the external GSM/UMTS antenna

LEDs

System LED: Green Steady OK


Red Steady Error


Status LED: Green Steady OK


Red Steady Error


Comm LED: Red Steady Communication error

2.8 Web interface unit

The main module features a web interface for a comfortable local parametrization of the SmartKKS instrument. In addition to the visualization and input via the touch display, you can configure deep-level settings and view more detailed operating data.

You can open the web interface with a notebook, for instance, which needs to be connected to the main module via an Ethernet cable. It is also possible to connect a suitable and appropriately configured WLAN router to the Ethernet port of the main module to open the web interface via WLAN.

2.9 Fan

The temperature-controlled fan ensures a homogeneous distribution of the air inside the housing as required. In combination with the aluminium housing, a good heat dissipation is achieved. Ventilation openings through which dust could enter the inside of the housing are not needed.



3 SmartKKS software platform

The SmartKKS system consists of the SmartKKS instruments and a related SmartKKS software platform.

The software platform is used for the remote control and remote monitoring of the instruments. The instruments transmit the measured information to the software platform where it is saved and provided to the user for further analysis.

Communication between the software platform and the instruments can be at any time, the instruments can be accessed at all times.

The configured CCP protection zones and all CCP instruments are organised and managed via the software platform. The evaluation of the measured CCP data can be visualized in a table or in a chart. The measurements that are required on a regular basis so that the efficiency of the CCP can be evaluated are configured via the “Routine measurement”. For this measurement, you can choose the points in time of the measurements and the parameters to be recorded.

The “Online measurement” function is used to transmit selected parameters as real time information to the software platform. In this way, the values currently measured on the protected object, such as the current protective current or the external interference of the protected object through alternating current railways can be visualized.

The software platform can be accessed via the SmartKKS web site. Its use esimply requires a web-enabled device such as a PC, notebook, tablet or smartphone. A safe and secure server solution in combination with a personalised access protects against data misuse. In addition, the web server solution offers the advantage that the user does not have to take care of maintenance, backup or upgrades.

Later on, the software platform will also be offered as a local solution which can directly be installed in the operator’s IT system.

Expanding the features, integrating CCP remote control technology from other suppliers and providing IT interfaces for a data exchange with other software programmes represent fixed components of the SmartKKS concept.

Figure 8: SmartKKS software platform



Figure 9: SmartKKS software platform



4 Functions of the SmartKKS basic version

4.1 CCP operation

Together with the SmartKKS software platform, the SmartKKS instruments form a complete system for the operation and remote monitoring of the cathodic corrosion protection of buried objects.

The requirements of remote monitoring listed in the DVGW Rule Set, Code of Practice GW 16, are met in relation to the properties of the protected object.

In general, the defined monitoring categories

1a

1b

2a

2b

are safely achieved with SmartKKS.

Even the highest category 2c can relatively safely be achieved with SmartKKS which represents an outstanding innovation in the field of CCP.

4.1.1 Parametrization

The instruments are parameterized via the software platform, the instrument touch display and via the web interface that can directly be accessed in the instrument with a notebook.

The following settings can be configured amongst others:

Protection voltage

Permanent pulsing with selection of pulse ratio, e.g. 12/3

Monitoring measurement/routine measurement:

Selection of the measurement times >= intervals of 5 min.

Selection of pulse ratio, e.g. 12/3

Selection of measured values

All relevant information of the instrument, such as the GPS coordinates of the location, is stored in the software platform.

4.1.2 Routine measurement

The routine measurement describes a monitoring measurement for the remote monitoring of the cathodic corrosion protection that is routinely repeated.

The selected parameters to be measured are read at the configured points in time and transmitted to the software platform.

The readings are available for a tabular and graphical evaluation. The graphical evaluation offers additional features such as zooming. A comment can be entered for every reading. The readings can be exported to different data formats and saved locally.

The basic version of the system can monitor two separated protection zones. The protective current, the potential and external interferences can be captured in parallel, but independent of each other.



4.1.3 Online measurement

The online measurement can be started anytime via the software platform. The specified measured values are transmitted in real time with their current readings. The course of the readings is shown in a continuous chart. With this function, the current situation in the measured location can be visualized to capture, for instance, the effect of alternating current railways at the specific point in time.

Figure 10: Online measurement, pipe potential, protective current

4.2 Analysis of external interferences

The recording and evaluation of measurement data of SmartKKS provides functions to capture and evaluate external interferences on the protected object.

This includes:

16 2/3 Hz shares externally induced into the protected object through alternating current railways

50 Hz shares externally induced into the protected object through power supply grids

Monitoring of other technical frequencies which have an inductive effect on the protected object

Based on the measurement and evaluation of the mentioned external interferences, it is possible to identify measures that extend the service life of buried metallic pipes of gas networks.



4.3 Detection of external contacts

SmartKKS offers the possibility to detect external contacts to cathodically protected, buried pipelines.

These external contacts can be short-term metallic contacts with a high resistance compared to the ground resistance of the pipeline.

Typical external contacts of this type with the pipeline are excavator contacts or when cutting ditches.

The monitoring is autonomous. The SmartKKS instruments permanently read the corresponding parameters on the pipeline and evaluate them. As soon as an external contact is detected, an alert message will be sent to the software platform, to a cellular phone via SMS, via e-mail or to a control station.

The detection of external contacts depends on the length of the protected zone, its ground resistance and the type of external interference. The interrelations differ from protected object to protected object and need to be evaluated in the specific situation in relation to the expected detection behaviour.

5 Quick reference for the SmartKKS installation

1. Mount control cabinet

a. Ensure sufficient distance for cooling (at least 10 cm on all sides)

2. Connect grounding to control cabinet (at least 6 mm²)

3. If existent: Mount DCF77 module (Meinberg RU-226) (ensure orientation towards Frankfurt)

Connect DCF77 module (Meinberg RU-226) to measurement module

4. Connect measurement signals to measurement module

1: Reference electrode

2: Pipe potential

3: Anode potential

4: Additional measurement channel

5: Additional measurement channel

5. Connect anode and pipe to power supply module. Always connect both terminals even if you only connect one protection zone. A 2.5 mm² cable must be used.

6. Connect the 230 V power supply of the primary power unit

a. Ensure de-energisation (switch off fuse)

7. Plug in microSIM with PIN disabled into the main module

8. Switch on instrument via the fuse

9. Configure the instrument after the start (about 30 seconds)

a. Configuration via the display

b. Configuration via the web interface

c. Remote configuration via the control level (VPN)

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